Hitchiner Manufacturing Co. Inc. (Hitchiner) has recognized two engineers for developing an innovative horizontal shell process that is now being used in production. The new process, which is patent pending, is just one of a number of innovations that have been developed in-house and put into use during Hitchiner’s 75 year history.

Tom Bonaventura, Process Owner Front End, and Joe Michalik, Advanced Equipment Engineer, were awarded Hitchiner’s Invention Use Award by John Morison III, Chairman, CEO & President. The award recognizes their contributions to developing the horizontal shell equipment  and process , which increases efficiency by taking advantage of the round mold shape used in Hitchiner’s distinctive counter-gravity casting technology.

How it works

Unlike the traditional process of preparing molds by dipping assemblies into a vat of slurry, Michalik and Bonaventura’s process pours a slurry “curtain” over the assembly and then passes it through falling stucco, allowing the facility to simultaneously process shells and reduce the amount of slurry in use at a given time.

The process has proven to be extremely effective and according to Scott Biederman, Hitchiner’s Vice President, Technology and President, Metal Casting Technology, Inc. (MCT), it can be used for 80% to 90% of the parts Hitchiner produces. 

From Idea to Innovation

The work to develop and test the process and equipment was done MCT, where both engineers work. MCT is a wholly owned research and development subsidiary of Hitchiner. Under the direction of Biederman, new ideas, technology, and processes are developed and tested with these goals in mind: to find a better way to deliver quality products to customers and improve the overall quality of what Hitchiner can deliver.

“We’re always looking to advance technologies. That’s been the Hitchiner way for 75 years,” said Biederman. “This is an example of a new way of doing things that gives us a competitive advantage.” 

Testing ideas from initial concept into production use is what makes MCT and Hitchiner stand out as a top place to work for engineers looking to innovate. Over the past 35 years, MCT has had 37 patents submitted and approved, and several others are pending. Patents are not the only form of innovation Hitchiner recognizes. The Invention Use Award has also been given to other significant contributions to improving the work Hitchiner does and in developing innovative, proprietary processes and equipment.

Bonaventura and Michalik worked on this project as part of Hitchiner’s engineering development program for young engineers which is led by Bonaventura.  The program gives new engineers the opportunity to work on MCT’s pilot scale equipment for investment casting, as well as the fully-equipped ceramics and metallurgy laboratories to learn the fundamental principles of countergravity investment casting.   The two engineers proved the concept for the new shell system with a hand operated unit, and then they were closely involved with the team that designed and produced  a pilot production unit that created molds on  three shifts seven days a week for well over a year.  

Biederman noted that  Michalik has been recognized for one other patent developed while at Hitchiner, and both of these technologies are in production.

“It’s really a great opportunity for young, innovative engineers who want to contribute at a high level,” said Biederman.